Vehicle window assembly for mounting interior vehicle accessories

ABSTRACT

A modular vehicle window assembly is provided which has attached thereto interior vehicle accessories. In a preferred embodiment, the window panel assembly includes a window panel disposed within or covering a window opening formed in the vehicle. The window panel may optionally contain a conventional gasket or sealing structure to provide a weather-tight seal in the window opening. Supported on and interconnecting to the interior surface of the window panel are any one of a number of different accessory configurations, including centerline, island, and peninsular overhead consoles providing storage space, overhead lighting, and air conditioning vents for use by the occupants. Other accessories which may be used include an instrument display assembly, a control assembly, a window shade assembly, and a hand-hold assembly. The interior accessories may be interconnected to the window panel by a variety of fasteners which provide the ability to quickly interchange an interior component and/or provide sufficient tensional strength characteristics to suspend the interior accessory from the interior surface of the window panel. Also provided are a perimeter storage and concealment system for providing a finished interior and storage capability about the interior of the window opening. Preferably, the assembly is used in the roof area of the vehicle such that the accessories are supported overhead of the passenger compartment.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a continuation-in-part of copending application Ser. No.08/420,233, filed Apr. 11, 1995.

BACKGROUND OF THE INVENTION

The instant invention relates generally to vehicle accessories, andparticularly to vehicle accessories attached to glass and a method forattaching such accessories to glass.

Generally speaking, vehicle interior accessories have been attached to apanel which, in turn, has been attached to some portion of the vehicle.Examples include the accessories mounted in the dashboard or instrumentpanel area and overhead consoles bolted to an interior roof panel. Otherthan the rear view mirror, accessories have not been attached to thewindshield/windscreen or overhead moon roof/sun roof because there was aconcern for visual impairment and because the attachment techniquesoften required drilling a hole through the glass to keep the accessoryfrom falling off. As a result, overhead consoles, visors, grab handles,and the like have always been fastened to the roof cross members,pillars, interior dash and headliner panels, or specially providedmembers to support the accessory. These types of assemblies requireadditional time and expense to install in the vehicle and have not beenwell adapted to installation as a module or unit.

Additionally, with the current trend of producing more glass area invehicles, space for storage or other accessories decreases at theexpense of glass. Currently, there is no viable means for providingadditional space for accessories or storage in the areas occupied byglass.

SUMMARY OF THE INVENTION

It is a purpose of this invention to provide a window panel assemblywhich can be installed in the vehicle from the vehicle exterior as amodular unit which includes one or more accessories or accessorymounting members pre-attached thereto so that the accessories areappropriately placed in or on the vehicle at the time the window panelis installed. Such an assembly is preferably shipped to the vehicleassembler as a preassembled unit, resulting in a decrease in assemblytime and fewer man hours to complete the assembly which translates intoa financial savings to the manufacturer.

Generally, the invention includes a window assembly having a window ortransparent panel configured to close a window opening in a passengercompartment of the vehicle. The panel includes opposing surfaces.Deposited or attached to one surface of the panel in a predeterminedgeometric pattern is an opaque layer of material. Attached to onesurface of the window panel in an area generally covered or concealed bythe opaque layer are one or more accessories or accessory mountingmembers configured to be located on the vehicle when the panel isattached to the vehicle.

A number of attachment methods and mechanisms are provided such that theaccessories may either be detachable or permanently fixed to the panel.A range of accessory options can be preassembled by the panelmanufacturer and provided to the vehicle assembler as modules which canthen be quickly and easily installed on the vehicle from the vehicle'sexterior.

According to one form of the invention, a vehicle window panel assemblyis provided, including a window panel having opposing surfaces and ageometric shape configured to fit in a window opening. An opaque layeror coating covers a predetermined area of the inner surface of thewindow panel. Attached to the window panel in an area generallyconcealed by the opaque layer is an interior accessory member configuredto be attached to the inner surface of the window panel. An adhesivebonds the accessory member to the inner surface of the window panelconcealed by the opaque layer.

In another form of the invention, a modular window panel assemblyconfigured to close an overhead window opening of a vehicle is provided,including a window panel having inner and outer surfaces and of a shapeconfigured to fit within the overhead window opening of the vehicle. Anattachment member is provided which is bonded to the inner surface ofthe window panel. An interior accessory of the vehicle is interconnectedto the inner surface of the window panel by the attachment member.

According to another form of the invention, a window panel is providedto close an opening in the vehicle. The window panel is preferablyformed from a sheet of transparent material having interior and exteriorsurfaces terminating in a peripheral edge. At least a portion of theinterior surface receives an opaque coating to conceal portions of theinterior surface and provide a cosmetically appealing finish. Attachedto the interior surface of the window panel having the opaque coating isan accessory preferably including at least one of a storage compartment;an overhead island, peninsula, centerline, or peripheral storagecompartment; power strip; assist handle, sun visor, or shade; andretractable sunshade. The accessory is preferably fastened to the windowpanel by one of several attachment members, including at least one of ahook-and-loop fastener assembly, DUAL LOCK™ tape, bonded stud fastener,an adhesive, a double-sided adhesive tape, and a polymeric bead.

According to still another form of the invention, a sun visor assemblyis provided which includes at least one mounting member configured to bebonded directly to the upper, inner surface of a windshield. Theattachment point is preferably near the upper edge of the windshield inan area containing an opaque coating so the attachment point isconcealed from the exterior of the vehicle. The mounting member issecurely bonded to the opaque coating by an adhesive capable ofwithstanding substantial static and dynamic forces commonly associatedwith visor assemblies over a range of environmental conditions.

The advantages offered by this invention are numerous, including reducedassembly time by the automobile manufacturer by being able to preciselylocate the accessories on the window panel which translates into agreater production rate. Additional advantages include a wide range ofoptions using substantially uniform or universal attachment procedures,and the ability to support accessories on a window panel without usingfasteners extending through the window resulting in a significantreduction in window breakage. Further, use of the invention allows theinclusion of larger window or sun/moon roof areas without sacrificingthe inclusion of improved storage, instrument, grab handle, or sunshadeor visor support areas. Additionally, this invention provides thoseadded accessories in the areas occupied by the vehicle glass.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

A better understanding of the invention and the advantages providedthereby may be obtained by reference to the specification and theattached drawing figures, wherein:

FIG. 1 is a top plan view of the exterior of a vehicle embodying theinvention;

FIGS. 2A, 2B, and 2C are perspective, top plan, and sectional views,respectively, of the interior roof area of a vehicle illustrating oneembodiment of the invention;

FIGS. 3A, 3B, 3C, 3D, and 3E are fragmentary sectional views of theinterior roof area of a vehicle illustrating alternate embodiments ofattachment members used in the invention;

FIGS. 4A, 4B, and 4C are perspective, sectional, and top plan views,respectively, of the interior roof area of a vehicle generallyillustrating an alternate embodiment of the invention;

FIGS. 5A, 5B, and 5C are perspective, sectional, and top plan views,respectively, of the interior roof area of a vehicle generallyillustrating a second alternate embodiment of the invention;

FIGS. 6A, 6B, 7, 8, and 9 are perspective or plan views of the interiorroof area of a vehicle generally illustrating additional embodiments ofthe invention; and

FIGS. 10 and 11 generally illustrate yet another embodiment of theinvention as applied to the windshield.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Generally

With the general trend in the auto industry to maximize visibility forthe driver and occupants, window area is increasing and structural steelarea is decreasing. As a result, conventional attachment points in modemvehicles for accessories above the instrument panel have also beenreduced. An example of a conventional modem vehicle 20 reflecting thistrend is shown in FIG. 1.

Referring to FIGS. 1, 2A, 2B, and 2C, one embodiment of a window panelassembly 22 of this invention is shown on a roof 26 of the vehicle 20.The window panel assembly 22 generally includes at least one sheet orpanel 28 of glass, plastic, or composite laminate of a thickness andshape configured to be received within or over the window opening 24formed in the roof 26. Although roof opening 24 is shown as a generallyrectangular shape located in the forward section of the roof with itslongitudinal axis transverse to the longitudinal axis of the vehicle, itis contemplated that the opening may take on any one of a number ofshapes and locations including occupying the entire roof panel 26. In apreferred embodiment, the window panel 28 includes an inner surface 30and an opposite, generally parallel outer surface 32, both terminatingin a peripheral edge 34 which generally defines the geometric shape ofthe window panel. The panel 28 is preferably made from transparent ortinted glass which may be tempered, laminated, or otherwise strengthenedusing conventional techniques. Additionally, panel 28 may be curved,bent, or generally planar to conform to the desired need or application.

In the embodiment shown in FIG. 2C, panel 28 includes a gasket orgrommet 36 attached thereto, through one of extruding or molding priorto or on the peripheral edge 34, such as disclosed in commonly ownedU.S. Pat. No. 5,331,784, or deposited proximate the peripheral edge 34along the inner surface 30 to produce a flush glazing as disclosed incommonly owned U.S. patent application Ser. No. 07/898,094, entitledVEHICULAR PANEL ASSEMBLY AND METHOD FOR MAKING SAME, filed Jun. 12,1992, now U.S. Pat. No. 5,443,673, the disclosures of which are herebyincorporated by reference. The gasket or grommet 36 attached to theglass helps locate and seal the window panel assembly 22 in or over thewindow opening 24. Although not specifically shown in the drawingfigures, window panel 28 may also be attached to hinges or othermounting hardware. In the embodiment shown in FIGS. 2A-2C, the windowpanel 28 is disposed above and over window opening 24. The bent form ofthe panel produces an arched window panel wherein the edges receive agasket 36. The trailing edge includes a cosmetically appealing trimpiece 38 attached to gasket 36, such as disclosed in commonly owned U.S.Pat. No. 5,352,010.

Optionally, and preferably, deposited and fired on inner surface 30 ofpanel 28 is an opaque, and preferably black, frit layer or coating 40,and most preferably a ceramic frit layer, covering and concealing atleast a portion of the inner surface 30. The area or pattern of theinner surface 30 which receives opaque coating 40 will generally includea region from peripheral edge 34 inward, such as two or more inches, toconceal from the exterior any adhesive or mounting member attachingwindow panel 28 to the vehicle (FIG. 2B). Since ceramic frit coating 40includes a pigment of a desired color, preferably a dark tint such asblack or the like, the layer results in a permanent, second, or insidesurface coloration of the panel 28. When viewed from the opposite orouter surface 32, the transparent thickness of the panel colored andbacked by the tinted ceramic frit layer 40, provides an appearance ofdepth and richness which blends well with the surrounding painted orglass areas of the vehicle. One ceramic material used to form the opaqueblack, ceramic frit coating 40 is manufactured by CERDECCORPORATION--DRAKENFELD PRODUCTS located in Washington, Penn.

Accessories

As shown in the Figures, attached to the inner surface 30 of panel 28 isan accessory, in this case a storage compartment 42. Although a storagecompartment is shown, an accessory can include other structures,including objects or devices not essential in themselves, but add to thebeauty, convenience, or effectiveness of the vehicles. Examples includestorage compartments, lamps, power strips, information displays, grabhandles, sunvisors, interior trim components including headliners, sunshades, and the like, some of which are described in greater detailbelow. Referring to FIG. 2A, the footprint of the storage compartment isconcealed from the exterior of the window panel by the opaque coating40, which extends under and between compartment 42 and panel 28. Thestorage compartment 42 is suspended from the entire perimeter of panel28 and may contain a number of compartments, with or without doors, suchas designated by reference numerals 44 and 46, respectively. As seen inFIG. 2C, storage compartment 42 includes a top wall 48 and an opposingbottom wall 50 interconnected by an outer wall 52 and an interior wall54. Formed in interior wall 54 are openings for providing access tointerior compartment 56. Shelf inserts or doors 47 may be installed inthe openings as desired for access and finish (FIG. 2A). Doors 47 arepivotally mounted to fold or rotate outwardly on suitable pivots orhinges and may also include handles and latches for grasping andretaining the doors in closed positions. Attached to the exterior ofbottom wall 50 (FIG. 2C) is a portion of the vehicle interior headliner60 surrounding the opening. A lip or channel 62 depending from theinnermost edge of bottom wall 50 may be configured to receive an edge ofheadliner 60 to support the headliner and to provide a finished edge.The remainder of the headliner 60 may be attached to the interior of thevehicle roof in a conventional manner.

A number of fastening techniques are contemplated for attaching thestorage compartment 42 to the window panel 28. The same fasteningtechniques may also be used to attach the headliner 60 to thecompartment bottom wall 50. Referring to FIG. 3A, one embodiment 66A ofattachment member is shown interconnecting the top wall 48 of thestorage compartment to the inner surface 30 of the window panel 28 onopaque layer 40. In this embodiment, attachment member 66A is ahook-and-loop arrangement including a sheet of fibrous material 68attached to opaque layer 40 by an adhesive-backed webbing 70. Thefibrous material 68 is snagged or hooked by a plurality of polymericsplit loops or hooks 72 extending from an adhesive-backed webbing 74attached to the top of the storage compartment 42. An example of such afastening material is sold under the brand name VELCRO™. In theembodiment shown in FIG. 3A, the strip of fibrous material 68 or splitloops 72 has its protective backing removed to expose the adhesive andis adhered to either opaque layer 40 or the exterior of top wall 48 ofthe storage compartment. The cooperating, opposite half has its adhesiveprotective layer removed and is adhered in a corresponding pattern tothe opposing surface. When mated, a sufficiently strong bond orattachment is made to suspend the storage compartment from the innersurface of window panel 28. Using this type of attachment member orfastener assembly, the storage compartment 42 may be preassembled towindow panel 28 and shipped to the manufacturer who can install itsubstantially in or over the window opening from the exterior. If adifferent storage compartment configuration is desired, an exchange orsubstitution of compartments may be made quickly and easily.

FIG. 3B illustrates another embodiment of an attachment member 66 usedto interconnect the storage compartment 42 to the inner surface 30 ofthe window panel 28. In this embodiment, the attachment member 66B isformed from a DUAL LOCK™ brand tape manufactured by 3M Company ofMinneapolis, Minn. The DUAL LOCK™ brand tape consists of two halves 76,78 each having an adhesive backing which adheres each strip 76, 78 toone of the top wall 48 of the storage compartment 42 or the opaque layer40 on the inner surface 30 of the window panel 28. Extending from anopposite side of the strip 76, 78 are a plurality of pins 80 each havinga semi-spherical head 82 and having a fiat base 84 on the underside oreach head 82. With the two exposed faces of the DUAL LOCK™ tape forcedtogether, the spherical heads 82 are forced beyond each other such thatthe base portions 84 of the pins engage each other and lock the twostrips of tape together. The coupling of the two strips of tape is suchthat a straight pull or tension produced by the weight of the storagecompartment will not cause the two strips of tape to separate. Rather,in order to separate the strips, one strip of tape must be peeled awayfrom the other to cause the spherical heads to rotate and release thebase portions. As with the previous embodiment, similar interactingstrips of tape may be used to interconnect the bottom wall 50 of thestorage compartment with the headliner 60 to retain the headliner inplace about the opening.

FIG. 3C illustrates yet another embodiment 66C of the attachment memberused to interconnect storage compartment 42 to interior surface 30 ofwindow panel 28. In the embodiment shown, a metallic or polymeric post86 may have a flange or head at one end 88 bonded to opaque layer 40 onthe interior surface 30 of the window panel 28. An adhesive 90, such asdisclosed below, may be used to bond flange 88 to the window panel. Itis contemplated that a number of different posts may be used includingChristmas tree posts, ringed posts, threaded posts, or tapered posts,each of which may receive a particular capturing member including adisk, nut, or clip, configured to be received over the post 86 and berigidly attached thereto. Alternatively, post 86 may be a locating post.It is contemplated that a number of posts 86 will be attached in apattern on the opaque area 40 to receive storage compartment 42 anddistribute the weight about the interior of the window panel. The bondof post 86 to layer 40 of the interior of the window panel 28 providesthe capability of supporting a significant amount of weight and isintended to be a more permanent structure than the embodiment using theVELCRO™ brand fastener.

FIG. 3D illustrates a more permanent installation or attachment 66Dwherein one or more beads of adhesive 94 are deposited either inchannels 96 formed in the exterior surface of top wall 48 or on opaquelayer 40 on the inner surface of glass panel 28. With the adhesive beadsin place, the storage compartment 42 is pressed against the interiorsurface 30 and retained in place until adhesive beads 94 form a securebond such that window panel assembly 22 may be moved. Alternatively, anattachment member, such as a stud, clevis, post, or the like, may beattached first by the adhesive. Once cured, the vehicle accessory may beattached by the attachment member. In some instances, the attachmentmember may be integral with the accessory. A number of differentadhesives may be suitable for attaching the mounting member or vehicleaccessory to the window panel. These include moisture-activated, singlecomponent urethanes, moisture-activated silicones, thermally activatedsilicones, moisture-curable hot melt urethanes, thermally activatedepoxies, chemically activated acrylates, thermally activated modifiedepoxies, two-component urethanes, and thermally activatednitrite-phenolics. The preferred adhesive is a two-component urethanedescribed in greater detail below.

FIG. 3E illustrates yet another embodiment 66E of the attachment memberfor interconnecting the storage compartment to interior surface 30 ofwindow panel 28. In this embodiment, a double-sided adhesive tape 98 mayhave one side adhered to opaque layer 40 on inner surface 30 of windowpanel 28 and the opposite surface bonded to the exterior of top wall 48.One example of a suitable double-sided tape is disclosed in U.S. Pat.No. 5,352,010.

In addition to the attachment members provided above, a polymeric beador profile may either be post-attached, molded, or extruded onto theinterior surface of the panel to provide a substrate for attaching theinterior accessory. For example, a bead or profile of a thermoplastic orthermoset material may be attached to the interior surface of the panelin a number of ways including those described above. The interioraccessory, such as a storage compartment, could be attached to theprofile by any one of the same attachment mechanisms described above.

As shown in FIGS. 4A-4C, another embodiment of the window panel assembly100 may include an overhead accessory compartment or unit 102 dependingfrom the interior surface 104 of the window panel 106. It is preferredthat console 102 be located along the centerline of the vehicle, i.e.,the centerline of rectangular window panel 106 which extends transverseto the longitudinal dimension of the window. It is also preferred thatthe surface of console 102 adjacent window panel 106 be concealed by aband of frit coating or other opaque layer 108, such as shown in FIG.4C. In a fashion similar to the embodiments described above, theperimeter of window panel 106 may also include the opaque layer orcoating along the peripheral boarder in order to conceal the windowopening from the exterior of the vehicle. Preferably the boarder coatingextends continuously from the central band of layer 108.

Referring to FIGS. 4A and 4B, an overhead accessory, such as a storagecompartment 102, may be manufactured in one or more sections which maybe preassembled to the window panel 106 prior to installation in thevehicle or assembly may be completed in the vehicle after installation.In the embodiment shown in FIG. 4B, storage compartment 102 includes acentral or middle section 110 having a bottom wall 112, a forward wall114, and a rear wall 116. Walls 114, 116 may also terminate in flanges118, 120, the upper surface of which may be attached by an attachmentmember, such as described above at 66A, 66B, 66C, 66D, or 66E, tointerior surface 104 and opaque layer 108 of window panel assembly 106.Middle storage compartment 110 may also include a top wall 122, whichinterconnects walls 114, 116 and provides a larger surface area to beattached to the interior surface of the window panel 106 by one or moreattachment members.

Disposed at the leading end of compartment 110 and abutting front wall114 may be a forward storage compartment 124. The forward storagecompartment 124 may include a top wall 126 and a forward wall 128 whichextends downwardly and wraps around the bulkhead 130 at the top of thewindscreen 132. From the lower leading edge of the front wall 128 is abottom wall 134 which may contain one or more openings 135 for displaysor storage compartment doors. Lower wall 134 may be rigidly ordetachably fastened to forward wall 114 of middle compartment 110 usingone or more attachment members 66A-66E as described above. The portionof wall 128 and 134 disposed below bulkhead 130 may be used to supportthat portion of headliner 136 proximate windscreen 132. The attachmentmember (not shown) interconnecting the forward module 124 to theinterior surface of window panel 106 should provide sufficient bondingstrength to support headliner 136 at this position.

Attached at the opposite end of middle compartment 110 is a rearcompartment 140 which may be either an integral portion of middlecompartment 110 or consist of an entirely independent compartment havingan upper wall 142, a rear wall 144, and a bottom wall 146. In theembodiment shown in FIG. 4A, rear compartment 140 may contain anadditional storage compartment accessible by a door 147 and may alsocontain an interior lighting assembly 148. Middle compartment 110 shownin FIG. 4A may also be accessible through one or more access doors 150pivotally disposed on the sides of the compartment or may haveadditional access provided by doors formed in lower wall 112. Althoughoverhead module 102 is described as consisting of three storagecompartments, it is contemplated that module 102 may be formed as anintegral unit and be attached to interior surface 104 of window panelassembly 106 after window panel assembly 106 has been installed in thewindow opening 152 (FIG. 4B).

FIGS. 5A-5C illustrate yet another embodiment 160 of the inventionwherein the storage compartment or accessory 162 constitutes an islandsuspended from the central portion of the inner surface 164 of thewindow panel 166. Additionally, the perimeter of the window panel 166may have suspended therefrom a wall 168 to finish off the space betweenthe headliner 198 and the interior surface 164 of window panel 166.Island accessory or storage compartment 162 and perimeter wall assembly168 may be concealed from the exterior of the vehicle by a ceramic fritlayer or opaque coating 170 applied to those areas of the interiorsurface 164 of window panel 166 wherein the accessories 162, 168 areattached (FIG. 5C).

Referring to FIGS. 5A and 5B, storage compartment or accessory 162 mayinclude a top wall 172 and a bottom wall 174 interconnected by end walls176, 178. Likewise, top and bottom walls and the end walls may beinterconnected by lateral sidewalls 180, such as shown in FIG. 5A.Lateral sidewalls 180 or bottom wall 174 may contain one or more doors,such as pivotal or hinged doors 182, to provide access to the interiorcompartment 184 defined by the walls. In the island embodiment of theaccessory, such as shown in FIGS. 5A-5C, upper wall 172 may beinterconnected to interior surface 164 and the opaque layer 170 ofwindow panel 166 by any one of the attachment members 66A-66E describedabove and shown in FIGS. 3A-3E.

Depending from the perimeter of window panel 166 and concealing windowopening 186 formed in the vehicle roof 188, is a concealment or wallassembly 168. The wall or concealment 168 may be formed from one or moremembers having a top wall 190 and a bottom wall 192 interconnected by anouter wall 194 and an interior wall 196. The upper wall 190 may beinterconnected and attached to the interior surface of window panel 166in any one of the attachment members 66A-66E described above.Additionally, concealment 168 may contain one or more compartments, suchas described above with respect to FIG. 2A. Headliner 198 also may beinterconnected to the exterior surface of bottom wall 192 in a similarmanner. Alternatively, a channel, finger, or similar type of projection200 may extend from the exterior of bottom wall 192 or inner wall 196 todefine a channel which is configured to receive the edge of headliner198 surrounding the window opening.

As can be seen from the above embodiments, and particularly FIGS. 2B,4C, and 5C, the frit layer coating or opaque layer 40, 108, 170deposited on the interior surface of the window panel conformssubstantially to the regions of the window panel which receive theaccessory. This is referred to as the footprint of the accessory. Thefigures for the additional embodiments of the invention described belowdo not illustrate the particular pattern of the opaque layer or ceramicfrit layer described, and it is to be understood that the concealingpattern for the coating is provided under each accessory just as inFIGS. 2B, 4C, and 5C.

Now referring to FIGS. 6-9, FIGS. 6A and 6B reveal yet anotherembodiment of the invention wherein an overhead peninsular console 210is suspended from the interior surface 212 of the window panel 214 andincludes a forward compartment/display section 216 which extends overthe headliner 218 toward the windscreen 220. Forward compartment 216 maycontain an electronic or other visual display 222, for displayinginformation produced by a trip computer, electronic compass, and thelike. The peninsular portion of storage compartment 210 may contain astorage compartment 224 accessible through pivotal or other doors 225and also provide a vent such as 226 for providing temperature controlledair to the rear of the vehicle. Appropriate ducting or conduit may beprovided along the length of storage compartment 210, beneath headliner218, and through the A-pillar, such as 228. Additionally, electricalpower may be provided beneath the headliner and to accessory 210. Aconceal 208, similar to 168 described above, may depend from theperimeter portion of window panel 214 and support the edge of headliner218 to conceal the window opening formed in the roof of the vehicle.Additionally, conceal 208 may contain one or more compartments, such asdescribed above with respect to FIG. 2A.

As shown in FIG. 6B, the peninsular storage compartment or console 210may include a first portion 211 forming an exterior wall or housinghaving an upper flange 213 interconnected to the inner surface 215 ofthe window panel 217. An outer wall 219 of a concealment or perimeterstorage compartment 221 may have an upper flange 223 connected to theinner surface 215 in the same manner, with a lower end 227interconnected through an inner wall 229 to the leading edge 231 of theconsole 210. The leading edge 231 may also support that portion of theheadliner 233. The headliner 233 may also be attached or supported bythe perimeter concealment or storage compartment 221 in the same manneras described above.

In yet another embodiment of the invention, as shown in FIG. 7, a powerstrip 230 is attached to the interior surface 232 of the window panel234. Power strip 230 can be arranged in a number of orientationsalthough it is preferred that it be parallel to one of the edges of thewindow opening and proximate thereto such that a power cord isthmus 236may extend thereto in a cosmetically pleasing fashion. Power strip 230includes a channel 238 within which are received one or moreelectrically powered accessories 240, such as map lights and the like.Accessories 240 received within channel 238 are preferably movable toany one of a number of positions within channel 230 to suit the need ofthe operator in a manner like that of track lighting in buildings. Alsoshown in the figure, and constituting yet another embodiment of theinvention, are island storage compartments generally indicated as 242which may contain a battery operated light source, such as indicated by244, or also contain a single storage compartment 246 accessible viapivotal door 247 suitable to carry a pair of eyeglasses or otherrelatively small accessories, including an electric garage door opener.Storage compartments 242 may be located substantially anywhere alongsurface 232 of window panel 234. As in the previous embodiments, aconceal 248 may depend from the perimeter of window panel 234 to providean aesthetic transition between the headliner 250 and interior surface232 of window panel 234. Additionally, conceal 248 may contain one ormore compartments, such as described above with respect to FIG. 2A.

In each of the embodiments described above that may require electricalpower, such power can be provided either by a local power source, suchas a battery, or by a remote power source through a conductor. Wireconductors may be concealed by the vehicle accessory and headliner, orin the case of islands, by a decorative strip. Alternatively, in thecase of islands, a conductive film may be deposited or otherwiseattached to the window panel. Additionally, the conductors may besandwiched between the lamination of the window panel and exit therefromat the appropriate location for attachment to the accessory.

FIG. 8 is a bottom plan view of yet another embodiment 250 of the windowpanel assembly wherein assist or grab handles 251 may be interconnectedat opposite ends of the panel 252 to the interior surface 254 closest tothe vehicle doors. It is contemplated that the ends 256 of the assisthandles 251 may be adhesively bonded to the interior surface of thewindow panel. Other suitable fasteners may be devised which providesufficient tensional load capabilities. The assist handles 251 arecontemplated to be located proximate the perimeter of window panel 252,where window panel 252 is most capable of supporting any bending momentsor flexural strain in the glass sheet structure. As in the previousembodiments, the ceramic frit layer or opaque coating may extend aroundthe perimeter of the window panel in order to conceal the attachmentends or areas of the assist handles.

FIG. 9 is also a bottom plan view of a further embodiment of theinvention wherein a sun shade assembly 260 includes a housing 262interconnected to the inner surface 264 of the window panel 266 usingone or more of the attachment members as described above. It ispreferred that the shade mechanism 260 be disposed along a centerline ofthe vehicle. Extending from each side of the shade housing 262 is aretractable sun shade 268 retained within housing 262 on a rotatableroller mechanism. Each such shade 268 has a finished edge 270 which mayinclude a guide mechanism having opposing ends captured within channelsformed in the leading edge 272. Additional supports or stiffeners may beprovided to retain sun shade 268 proximate window panel 266. Africtional assistance may also be provided to retain window or sun shade268 at a desired position. Thus, the operator may extend sun shade 268from housing 262 to any one of a number of extended positions and, whendesired, may retract sun shade 268 back into housing 262. As in theprior embodiments, an opaque layer 275 may conceal the attachmentlocation of sun shade housing 262 to window panel assembly 266.Additionally, a perimeter portion 276 of window panel 266 may be coatedwith the opaque layer in order to conceal the race or track for the sunshade guide.

Alternatively, the concept of this invention may be used on other windowpanels of the vehicle, particularly in view of the trend to increase thearea of glass and decrease the size of the roof size and roof pillars.Referring to FIGS. 10 and 11, a vehicle windshield 300 is shown which ismade from tempered glass, plastic, or lamination of both. The windowpanel 300 has inner and outer surfaces 302, 304, respectively,terminating in a peripheral edge 306. As seen in FIG. 10, an upperperipheral edge, designated by reference 306a, is configured to fit inand seal the upper edge of the vehicle windshield opening. Bonded to apredetermined area of the inner surface 302 of the windshield 300 is anopaque coating or frit layer 308, as identified above. The frit coating308 preferably occupies an area from the peripheral edge 306 inwardlyabout 2 to 3 inches. Attached to the inner surface 302 of the windshield300 proximate the upper peripheral edge 306a and in the area containingthe opaque coating 308, is a sun visor assembly 310. Visor assembly 310includes at least one mounting member 312, and preferably two, which isbonded to the opaque layer 308 at a predetermined location by anadhesive 314 described below. The adhesive is designed to securelyattach the mounting members 312 to the panel in such a manner so as towithstand static and dynamic loads without failing, as described below.

Mounting member 312 may have any one of a number of configurationsdesigned to receive and retain one end 314 of a visor arm or bail 316extending through an opening and journal sleeve 318, 320, respectively,to permit rotation of the arm 316 about end 314. Although othertechniques may be used, the end 314 is generally shown to be retainedwithin sleeve 320 by a C-clip 322 retained in a groove 324 in the bail316. The opposite end 326 of the visor arm 316 may be received anddetachably retained by a support bracket 328, also attached to theopaque layer 308 on the inner surface 302 using the same adhesive. Thefunction and interaction of the bracket with a conventional visor iswell known and will not be described with any detail herein. Similarly,the visor arm or bail 316 and visor panel 330 may also be ofconventional construction and will not be described in detail other thanmentioning that the visor panel 330 may include a vanity mirror 332 andlamps 334. Electrical power for the lamps may be provided byconventional wire conductors extending through a hollow arm 316 and overthe windshield to the headliner or A-pillar. The exposed portion of theconductors traversing the windshield may be concealed by a decorativecover (not shown). Alternatively, electrical conductors can be made fromthin film deposited on and extending across a portion of the opaquecoatings to a point below or under the mounting member where they may becoupled to the electrical conductors extending from the visor assembly.

Because the visor assembly 310 is attached directly to the inflexibleinner surface of the windshield, it is preferred to keep the size of themounting members as small as possible so they do not appear obtrusiveand blend with the interior of the vehicle. Also, it is desirable toreduce the visibility of any structure traversing any portion of thewindshield to the visor assembly. Accordingly, a strong adhesive isrequired to bond the visor structure 310 to the windshield and anunobtrusive electrical connection is preferred since they may be exposedover a short distance.

Although the various embodiments of the invention described below aremade with specific reference to sunroofs, moon roofs, or other windowpanels mounted over the passenger compartment in the roof, the basicconcept can be applied to vehicle windscreens, side windows, backlights,and the like as well as other areas where it is desirable to depend astructure from a transparent or opaque, glass, plastic or laminatepanel.

Adhesives

In many of the preferred embodiments described herein, the preferredadhesives are two-component urethane adhesives which are "rapid set" and"rapid cure." Rapid set refers to a property exhibited by thetwo-component system, such that after mixing the components andrelatively promptly contacting the adhesive mixture with the objects tobe bonded together, the objects are held by the adhesive againstmovement resulting from their own weight or movement resulting fromapplication of a relatively slight force, within about 3 minutes orless, preferably within about 90 seconds or less, and most preferablywithin about 45 seconds or less from the time of mixing and applicationof the adhesive to the objects. "Rapid cure" refers to a cure time ofless than about 60 minutes, preferably less than about 50 minutes, andmost preferably less than about 40 minutes. That is, at least about 80percent, preferably at least about 90 percent, and most preferably atleast about 95 percent, of the physical characteristics of the curedadhesives are obtained within about 60 minutes from the time ofachieving the set phase of the adhesive. These two-component urethanesdescribed herein fully cure, or substantially so, within the timeperiods referred to for rapid cure. That is, the average molecularweight of the polyurethane chains and degree of cross-linking in theadhesive matrix does not significantly change after the period of rapidcure. A specific example of a two-component adhesive is described incopending patent application Ser. No. 08/420,233, filed Apr. 11, 1995,assigned to the assignee of this application, and incorporated herein byreference.

The rapid set, rapid cure, two-component adhesives will have numerousapplications in high-production rate manufacturing processes, therebyoften eliminating the requirement of fixturing components and otherwisehindering the manufacturing process. These adhesives will withstandrelatively high tensile, torque, or shear loads; extreme vibration evenunder high temperatures and after extended aging and thermal cycling;and resistance to adverse environmental conditions encountered byvehicular window assemblies, making them appropriately suitable for usein attaching vehicle accessories to vehicle windows. The rapid set,rapid cure, two-component urethanes described herein am able towithstand tensile and shear forces of at least 500 psi, preferably 700psi, and most preferably 800 psi, without separation from the underlyingglass surface or breakage of the glass substrate. These adhesives havebeen found to be useful for forming bonded assemblies comprising glassand dynamic load-bearing attachment members having low surface areamounting footprints, that are able to withstand relatively high loads orother stresses, significantly beyond the ability of conventionalsingle-component urethanes. Such low surface area mounting footprintsare preferably less than about 6 in², and in some instances, may be lessthan about 1 in². In addition, it has surprisingly been discovered thatthese adhesives do not impart deleterious mounts of stress to the glasssubstrate to which they are bonded.

The rapid set, rapid cure, two-component urethane adhesives describedherein exhibit surprising and remarkable ability to rapidly bond glassto other materials in such a manner that the resulting bond canwithstand highly localized loads without failing. As previouslyexplained, many new window designs require attachment of mountingmembers or other attachment members to glass which results in highlyconcentrated static loads and/or dynamic loads at the adhesive bond, asmight be the case in certain storage compartments or hand grips. Often,there is minimal available surface area on the glass or attachmentmember for bonding. Such minimal surface area limits the available areafor distributing these loads and stresses over the adhesive bond. It iseven more remarkable that the bonded assemblies described herein,particularly those utilizing the preferred adhesives, retain theirbonded configuration under high loads, while concurrently subjected toadverse conditions such as vibration and temperature extremes. It hasbeen found that bonded assemblies utilizing the rapid set, rapid cure,two-component adhesive described herein can withstand localized statictensile loads of at least 5 lbs/in² and as high as about 40 lbs/in², andin some instances significantly higher loads such as 80 lbs/in², withoutfailing between the original equipment manufacturer specification rangesof -40° C. to 100° C.

A wide array of materials may be bonded to glass by use of the preferredadhesives described herein. Such materials may include for examplemetals, coated metals, plastics, coated plastics, or composites orcombinations thereof. The thickness of the adhesive layer generallydepends upon the end use applications for the bonded assembly, thesurface characteristics of the glass substrate and the attachment memberto be bonded to the glass, and the required bond strengths. If theadhesive layer is too thick, elongation of the adhesive layer, forinstance upon application of a shear stress, allows movement between thebonded components or substrates and may result in creep and/or peel. Ifthe adhesive layer is too thin, the bonded assembly may have poordurability, insufficient squeeze out or component coverage, or otherphenomena in which adhesive material migrates away from the bondinterface. Moreover, if the thickness of the adhesive layer is notuniform, there may be regions on the surfaces of the bonded componentsthat have insufficient coverage of adhesive, thereby resulting in voidsor other undesirable variations in coverage. The preferred thickness forthe adhesive layer is from about 0.01 mm to about 4.0 mm, more preferredbeing from about 0.25 mm to about 2.0 mm, and the most preferredthickness being about 0.5 mm to about 1.0 mm.

The preferred embodiment method of adhering attachment members to glasssubstrates is to prime the glass surface, and deposit an effective mountof a preferred embodiment adhesive described herein on one or bothsurfaces of the attachment member and primed glass substrate to bebonded, and place the attachment member and substrate in the desiredposition for bonding. The term "effective mount" refers to an mount ofadhesive such that the attachment member that is adhered to thesubstrate is securely bonded thereto after curing of the adhesive.Typically, an effective mount is an mount that results in an adhesivelayer thickness of between about 0.01 mm and about 4.0 mm, morepreferably about 0.25 mm to about 2.0 mm, and most preferably from about0.5 mm to about 1.0 mm.

Preferably, the adhesive is applied to a glass frit layer which isapplied to the glass panel. Thus, in forming the glass assembliesdescribed herein, it is preferred that the various assemblies comprisesuch a glass frit layer on the surface of the glass substrate. The fritlayer helps to shield the adhesive applied thereto from the ultravioletradiation of sunlight. Exemplary descriptions of forming frit layers onglass surfaces are provided in U.S. Pat. No. 5,331,784, which isincorporated herein by reference. Optionally, the surface of the glassto be bonded may be cleaned prior to bonding such as by washing withisopropyl alcohol or a suitable detergent followed by drying. Similarly,the surface of the component or other substrate to be bonded to theglass may also be washed and dried prior to bonding.

In order to form such bonds, an effective mount of the adhesive isdeposited on the attachment member to be bonded, and/or to theappropriate area of the glass or frit layer at which the attachmentmember is to be bonded. The attachment member is then engaged with theglass or frit layer via the adhesive, and adhesive allowed to set. Uponcuring, a strong, durable bond is formed between the attachment memberand the glass. The preferred adhesive dispensing method is performed byusing a metering unit and a mixing unit to both mix and dispense theadhesive. The metering unit should preferably dispense a very accuratelycontrolled volume of each component to the mixing unit. This volume mustbe constant for a specific flow rate such that the ratio of theisocyanate component to the polyol component does not change as thetotal dispensed volume and flow rate change. Preferred metering unitsare gear pump-based dispensing units such as those supplied by EMC² ofSterling Heights, Mich. The most preferred metering units are adjustablegear pump-based units. The preferred mixing unit may be either a staticmix tube or a dynamic urethane RIM mix head like those supplied byAdmiral of Canton, Ohio; Cannon of Mars, Pa.; Kraus Maffai of Germany,and others. For applications involving most automotive bondedassemblies, the most preferred mixing unit is a static mix tube 0.25inches in diameter and 6 inches long, in association with a 24 elementKINEX®, a sequential reverse static mixer.

In order to promote uniformity and accuracy of dispense volume, mixing,and ratio control, it is most preferred that the isocyanate and polyolcomponents of the adhesives described herein be delivered to thedispense metering unit and mixing unit through thermally controlledlines, such as those provided by Hart Ind. Supply of Middletown, Ohio.It is also preferred that the adhesive material be deposited upon theglass or attachment members to be adhered to the glass, with the aid ofa robot. Robotic deposition or other automatic procedures promoterepeatability in both application and open time control that manualoperation may not be able to deliver. An example of forming a bondedvehicular glass assembly by robotic assembly is described in greaterdetail below. It may also be desirable to accelerate the set and curetimes of the adhesive. Acceleration of adhesive set and cure times canbe accomplished by heating and/or by utilizing chemical agents. The useof chemical agents is discussed in greater detail below. Acceleration byheating may be performed by induction curing, infra red heating, orother methods of heating the adhesive.

In the preferred embodiment of the two-component urethane adhesivesdescribed herein, the polyol component utilized includes one or morepolyols and one or more high amine density plural amine compounds,hereinafter referred to as HADPACs. The preferred mount of HADPACtypically ranges from about 2 percent to about 20 percent, and mostpreferably from about 5 percent to about 10 percent by weight of thepolyol component. In addition, the adhesives utilize a filler agent ineither the polyol component, the isocyanate component, or both. Thefiller agent is preferably utilized in an mount from about 15 percent toabout 50 percent of the total weight of the polyol and isocyanatecomponents. Moreover, the adhesives preferably utilize a particularratio of isocyanate functionality to hydroxy and/or amino functionalityof from about 0.9 to about 2.0, more preferably from about 1.03 to about1.4, and most preferably from about 1.1 to about 1.3.

A HADPAC (a high amine density plural amine compound) may be eitheraromatic or nonaromatic, having an amine to carbon ratio of from about1.0 to about 0.25:1 with the provisos that the compound (a) contain atleast 3 amine groups, except if the compound is aromatic, then thecompound may contain as few as 2 amine groups due to plate-like stackingphenomenon and (b) the compound contain from 2 to 24 carbon atoms. Themolecular weight range for these amines typically ranges from about 115to about 5000, and more preferably from about 210 to about 290. Aparticularly preferred HADPAC is a penta-amine or hexamine containing 11or 12 carbon atoms, such as the aminated reaction product ofpentaerythritrol, glucose, or sucrose. The most preferred HADPAC isaminated sucrose or aminated pentaerythritrol. The amination reactionmay be performed by reacting pentaerythritrol, glucose, or sucrose, withan excess of, for example, but not limited to, ammonia, methyl amine,ethyl amine, and other amino alkanes of the formula C_(x) H_(n) NH₂where x ranges from about 1 to about 20, and n is such that the alkaneis fully saturated. In a preferred embodiment, x is from about 1 toabout 6, and most preferably, from about 1 to about 3.

As will be appreciated by those skilled in the art, during formation andisolation of a HADPAC, there will typically be a distribution ofcompounds accompanying the HADPAC. Thus, it is recognized that thefunction of the HADPAC in the adhesives described herein stems from notonly from the HADPAC, but also from the distribution of relatedcompounds accompanying the HADPAC.

Although not wishing to be bound to any particular theory, it isbelieved that upon curing of the adhesives described herein,cross-linking occurs between the HADPACs, and isocyanate groups to adegree such that a higher cross-link density is achieved in thepreferred embodiment adhesives as compared to most other urethaneadhesives. The polyols in the polyol component may include polyols suchas diols, triols, tetrols, pentols, hexols, heptols, and octols.Examples of polyol compounds that may be employed in the polyolcomponent include, but are not limited to, propylene glycol, ethyleneglycol, glycerine, trimethylolpropane, 1,2,6-hexanetriol,pentaerythritrol, methyl glucoside, sorbitol, and sucrose. It isenvisioned that a wide array of polyalkylene glycols (ethylene,diethylene, dipropylene), various glycerine triols and trimethylolpropanes, and derivatives thereof could be utilized. Other preferredpolyols include polyether or polyester polyols with hydroxyl equivalentweights (hydroxyl equivalent weight is the molecular weight per hydroxylgroup in the compound) of between about 50 and about 2000, such as ablend of diols, triols, and pentols and sucrose initiated polyols. Forend use applications expected to be exposed to water or moisture,polyether polyols are especially preferred in view of their relativelyhigh degree of hydrolytic stability.

In addition to the previously noted preferred HADPAC, other amines maybe utilized in the polyol component. Such amines may be formed byreaction between propylene oxide and/or ethylene oxide, and aminecompounds or other nitrogen-containing compounds such as ammonia.Examples of suitable amine compounds for such reactions include, but arenot limited to, triethanol amine, ethylene diamine, toluene diamine,diphenylmethane diamine, diethylenetriamine, aniline,methyldiethanolamine, triethanolamine, trispropanolamine, diethyltoluelene diamine, and other alkyl amines.

Examples of the isocyanate compounds that may be utilized in theisocyanate component include, but are not limited to, diphenylmethanediisocyanate (MDI), typically polymeric MDI, and its isomers such as4,4'-MDI, 2,4'-MDI and 2,2'-MDI; and tolylene diisocyanate (TDI) and itsisomers. It is also possible to use other isocyanates, either alone orin combination with one or both MDI and TDI. The preferred combinationof isocyanates for the isocyanate component is a majority fraction ofMDI prepolymers, such as Dow Chemical's PAPI* 27, and minority fractionof monomeric isocyanates, having an iso-equivalent weight between 143and 181 (iso-equivalent weight is the molecular weight per isocyanategroup in the compound), and minority fraction of a mixture of polymericisocyanates such as a polymeric polyisocyanate available from DowChemical, dimers and trimers of MDI, and alternate pre-polymers of MDI.

One or more filler agents are incorporated in either the polyolcomponent, the isocyanate component, or both. Although not wishing to bebound to any particular theory, it is believed that the filler agentcreates a porous structure within the adhesive, which enables moistureto permeate into and throughout the adhesive to effect isocyanatecross-linking via urea formation with any unreacted isocyanates. Thepreferred mount of filler agent is from about 15 percent to about 50percent of the total weight of the polyol and isocyanate components.More preferably, the mount of filler agent is from about 20 percent toabout 30 percent of the total weight of the polyol and isocyanatecomponents. Most preferably, the mount of filler agent is about 25percent of the total weight of the polyol and isocyanate components.Examples of suitable filler agents include, but are not limited to,silicates such as magnesium silicate, silicas such as crystalline silicaand quartz silica, calcium carbonate, talc and combinations thereof. Thepreferred filler agent is a combination of talc and silica.

A typical urethane adhesive system employs a ratio of isocyanatefunctionality to hydroxy and/or amino functionality of from about 1.03to about 1.07. A ratio higher than about 1.07 leads to an adhesive whichis excessively brittle and relatively slow curing. A ratio less thanabout 1.03 leads to a cured adhesive which is too soft for use in mostindustrial applications. The preferred embodiment adhesives, it has beensurprisingly discovered, utilize a ratio of isocyanate to hydroxy and/oramino functionality of from about 0.9 to about 2.0, more preferably fromabout 1.03 to about 1.4, and most preferably from about 1.1 to about1.3. These ratios are desirable since by utilizing greater amounts ofisocyanate, the resulting cured adhesive has greater heat resistancewithout sacrificing elongation or tensile strength.

A wide array of optional components may be incorporated in the preferredadhesives depending upon the application and desired end userequirements for the bonded assembly. For example, various UV blockers,stabilizers and absorbers may be incorporated in the adhesives tominimize adhesive degradation from sunlight. Chain extenders may beutilized such as ethylene glycol, butane diol, ethylene diamine, anddiethyl toluene diamine. Various cross-linking agents may be utilizedsuch as, but not limited to, oxypropionated sucrose, aliphatic amines,pentarythrathols, aminated polyols or high hydroxyl number materialssuch as 1,2,6-hexanetriol, 1,1,3-trimethylolpropane, and glycerine forexample. In addition, pigments or colorants may be added to theadhesives. One or more diluents or thixotropic may be added to theadhesive composition to modify the viscosity and related processingcharacteristics of the resulting compositions. It may also be desirablethat one or more additives such as thermal stabilizers, antioxidants,and surfactants may be utilized in the adhesive. All the foregoingoptional components may be added to the polyol component, and whereapplicable, to the isocyanate component, or to both prior to mixing, orto a third or other component which can be added to the mixture prior tosetting to form the desired adhesive.

Depending upon the characteristics desired for the setting and curingphases of the adhesive, it may be desirable to add one or more catalyststo accelerate the setting and curing phases. Examples of catalysts forthe adhesives of the preferred embodiment include, but are not limitedto, tertiary amines such as 1,4-diazabicyclo [2,2,2] octane (triethylenediamine), N-methylmorpholine, N-ethylmorpholine, triethylamine,N-methyldiethanolamine, N,N-dimethylaminoethanol,N,N-diethylaminoethanol, triethanolamine, tetramethylguanidine,N,N,N',N'-tetramethylethylenediamine, N,N-dimethylC₁₀ -C₁₆ amine,N,N-dimethylcyclohexylamine, N,N-dimethylpiperazine,1,2,4-trimethylpiperazine, bis-(2-hydroxypropyl)-2-methylpiperazine,bis-(beta-dimethylaminoethyl) ether, and organotin compounds such asstannous octoate, stannous oleate, dibutyltin dilaurate, and dibutyltindiacetate.

There are commercially available urethane adhesives which exhibit thepreferred rapid set, rapid cure, and high-strength characteristics,which provide surprisingly superior bonds between glass and othercomponents or materials. One such commercially available two-componenturethane adhesive having all the above-described properties, and whichis the most preferred adhesive, is Essex 73100 isocyanate component, andeither 73002 or 73003 polyol component available from Essex SpecialtyProducts, Inc., a subsidiary of The Dow Chemical Company. The Essex73100 isocyanate component comprises a proprietary polyurethaneprepolymer(s) which is believed to primarily comprise prereacted,relatively long, branched chain molecules of diphenylmethanediisocyanate (MDI) reacted with a combination of relatively short andmoderate chain length diols, triols, and moderate chain length diamines.It is further believed that the ends of these chain molecules areblocked with isocyanate groups, and there exists a proportion of freeMDI molecules that are present and available for reaction. The 73100component further comprises various fillers, such as magnesium silicate,crystalline silica, and calcium carbonate. The solids content andapproximate amount of filler agents in the Essex 73100 component isabout 24 percent. The Essex 73002 polyol component comprises proprietarypolyurethane prepolymer(s) of polyols, diols, N-phenol diethanolamine,and a pentaamine that is initiated from pentaerythritrol and sucrosemolecule, i.e. , a HADPAC. The 73002 polyol component further comprisesfillers, catalysts, and likely includes surfactants. The fillers arecalcium carbonate and quartz silica. The catalyst is an amine-basedcatalyst. The solids content and approximate amount of filler agents inthe 73002 component is 27 percent.

This most preferred, commercially available adhesive system has acombination of properties and characteristics that render itparticularly well suited for use in forming automotive window or panelassemblies and for installing such assemblies in vehicles. Thecombination of properties include relatively high stability andresistance to water, minimal creep even at relatively high temperaturesthereby resulting in a structurally rigid bond, ability to impartremarkably low stress upon the underlying substrate upon curing, and aspreviously described, relatively fast set and cure times. The presentinventor has further found that this adhesive provides surprisinglystrong and durable bonds between glass and other materials. Thisadhesive is particularly well suited for forming bonds between vehiclemounting surfaces and attachment members that are subjected to and whichbear dynamic loads.

As previously noted, it may be desirable to utilize an adhesion promotorand/or a palmer. Adhesion promoting compounds generally include silanesand amino silanes such as available from Dow Coming, Lord Chemlock,General Electric and Essex. Specific examples includediamino-tri-methoxy silanes available under the designations LordChemlock 134/144 and similar materials from Essex such as Essex 435.18and 435.20. Other silanes not limited to diamino or tri-methoxy formsmay also be suitable. A second group of adhesion promoters are titaniumor zirconium coupling agents such as available from KenrichPetroChemical Inc. of Bayon, N.J., which enhance the bonding ability ofthe adhesive to the substrate. Alternatively, or in addition to anadhesion promoter, one or more primers or single-component urethaneadhesives may be used such as urethane based, isocyanate-rich,moisture-curable, urethane prepolymers such as Morton Yokohama MS-90available from Morton International of Ridgewood, Ill. or Essex 435.20a.Additional examples of substrate primers include but are not limited toEssex 435.32, for applications in which the substrate to be bonded toglass is metal or plastic. Although these adhesion promoters or primersare preferred, they are not the only adhesion promoters or primersavailable which may be equally if not more suitable for the application.

The adhesion promoter and/or primer applied to the glass surface shouldform a layer having a thickness such that the entire surface of the areaof the glass to be bonded, or substantially so, is wetted by theadhesion promoter or primer. The preferred thickness range for theadhesion promoter or primer materials is from about 0.01 mils to about3.5 mils, more preferably from about 0.05 mils to about 2 mils, and mostpreferably from about 0.1 mils to about 1.0 mils. It is undesirable toapply an excessive amount of adhesion promoter or primer on the glass assuch leads to interlayer polymeric silane cross-linking. Such silanepolymerization results in a much weaker bond than the silane-urethaneprimer link. Many commercial suppliers for adhesion promoters or primersrecommend that after application of adhesion promoter or primer to thesubstrate to be bonded, that excess promoter or primer material be wipedoff with a clean cloth. This wipe-off step results in additional timeand labor, which is clearly undesirable at the commercial level. A moredesirable way of removing excess adhesion promoter or primer materialafter application is to allow solvents in those materials to flash off.Sufficient flash off was found to occur at ambient temperatures in aperiod of only from about 5 seconds to about 15 minutes.

One or more layers of adhesion promoters and/or primers are preferablyapplied to the glass substrate and/or other substrates or attachmentmembers to be bonded thereto prior to bonding. A preferred combinationis to utilize an amino silane adhesion promoter, such as Essex 435.18silane coupling agent, adjacent the glass surface, followed by a layerof a single-component urethane primer, such as Essex 435.20A primer,deposited on the layer of adhesion promoter. The adhesive is thendeposited on the primer layer. It is most preferred to apply thetwo-component urethane adhesive to the adhesion promoter and/or primerwithin 96 hours of application of the adhesion promoter and/or primer tothe glass surface.

The preferred embodiment bonded assemblies and panel assembliesdescribed herein may be incorporated in vehicles such as automobiles,trucks, vans, minivans, and utility vehicles; recreational vehicles suchas motor homes, campers, and trailers; other vehicles such as buses,trolleys, trains, commuter vehicles, and airplanes; marine vehicles suchas boats and other watercraft; and nearly any structure utilizing aglass panel or substrate for which there exists a need to securelyadhere other components to, or to securely affix one or more glasspanels thereto. Such window panel assemblies are especially useful in avariety of vehicles and especially for large area windows, andparticularly for large area flush-mounted glazings, such as are used asfront, rear, and side windows, and as sunroofs, in automobiles,minivans, vans, tracks, and buses and which utilize a window panel thatweighs at least about 3 kilograms (with a window panel weight of atleast 5 kilograms common for front and rear windows, and for sidewindows on minivans and larger vehicles) and with a window panel area ofat least about 250 square inches.

The above description is considered that of the preferred embodimentsonly. Modification of the invention will occur to those skilled in theart and to those who make and use the invention. Therefore, it isunderstood that the embodiments shown in the drawings and describedabove are merely for illustrative purposes and are not intended to limitthe scope of the invention, which is defined by the following claims.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. A vehicle window panelassembly, comprising in combination:a window panel having an innersurface and an outer surface, and of a geometric shape to fit within awindow opening of a vehicle; an opaque layer on said inner surface ofsaid window panel; a vehicle storage compartment attached to said innersurface of said window panel; and an adhesive bonding said vehiclestorage compartment to said inner surface of said window panel.
 2. Thevehicle window panel assembly as defined in claim 1, wherein said saidopaque layer on said inner surface corresponds to a footprint of saidvehicle storage compartment attached to said inner surface of saidwindow panel.
 3. The vehicle window panel assembly as defined in claim2, wherein said vehicle storage compartment includes at least oneselected from the group consisting of a lighting system, an instrumentdisplay system, a system control panel, a window panel shade assembly, ahand grip, and an interior trim component.
 4. The vehicle window panelassembly as defined in claim 2, wherein said footprint of said vehiclestorage compartment includes at least one selected from the groupconsisting of an island, a peninsula, a perimeter margin, and a striptraversing said inner surface of said window panel.
 5. The vehiclewindow panel assembly as defined in claim 1, further including anattachment member bonded to said inner surface of said window panel forcoupling said vehicle storage compartment to said inner surface of saidwindow panel.
 6. The vehicle window panel assembly as defined in claim5, wherein said attachment member includes at least one selected fromthe group consisting of a hook-and-loop fastener, an interlocking pinfastener, a threaded fastener, a double-sided tape, a post, and apolymeric profile.
 7. The vehicle window panel assembly as defined inclaim 6, wherein said polymeric profile includes at least one selectedfrom the group consisting of a molded polymeric profile and an extrudedpolymeric profile.
 8. The vehicle window panel assembly as defined inclaim 7, wherein said polymeric profile is integral with a gasketattached to said window panel for attaching said window panel in saidopening of said vehicle.
 9. The vehicle window panel assembly as definedin claim 1, wherein said adhesive is selected from the group consistingessentially of single-component adhesives, multi-component adhesives,chemically activated adhesives, thermally activated adhesives,moisture-curable adhesives, thermoplastic adhesives, and thermosetadhesives.
 10. The vehicle window panel assembly as defined in claim 9,further including an adhesion-promoting compound between said opaquelayer and said adhesive.
 11. A modular overhead window panel assemblyfor a vehicle, comprising in combination:a window panel having inner andouter surfaces; an attachment member bonded to said inner surface ofsaid window panel; and a storage compartment assembly attached to saidinner surface of said window panel by said attachment member.
 12. Themodular window panel assembly as defined in claim 11, further includingan adhesive between said attachment member and said window panel forbonding said attachment member to said inner surface of said windowpanel.
 13. The modular window panel assembly as defined in claim 12,further including an opaque coating on at least a portion of said innersurface of said window panel and receiving said adhesive.
 14. Themodular window panel assembly as defined in claim 11, wherein saidattachment member is selected from the group consisting essentially ofat least one of a hook-and-loop fastener, an interlocking pin fastener,a threaded fastener, an adhesive tape, a polymeric profile, and a metalpost.
 15. The modular window panel assembly as defined in claim 11,wherein said storage compartment assembly includes an interior trimcomponent.
 16. The modular window panel assembly as defined in claim 15,wherein said storage compartment assembly includes at least one selectedfrom the group consisting of a lighting assembly, an instrument displayassembly, a control assembly, a window shade assembly, and a hand-holdassembly.
 17. The modular window panel assembly as defined in claim 15,wherein said storage compartment assembly includes at least one selectedfrom the group consisting of a headliner and a trim molding.
 18. Awindow panel assembly for a vehicle, comprising in combination:anoverhead window panel to close an overhead window opening of thevehicle, said window panel having interior and exterior sidesterminating in a peripheral edge; an overhead interior vehicle accessoryassembly attached to said interior side of said window panel, saidaccessory assembly having a footprint facing said interior side of saidoverhead window panel; an opaque area between said window panel and saidaccessory assembly, and said opaque area generally corresponding to saidfootprint of said accessory assembly; and an attachment memberinterconnecting said accessory assembly to said interior side of saidwindow panel.
 19. The window panel assembly as defined in claim 18,wherein said opaque area defines a perimeter.
 20. The window panelassembly as defined in claim 18, wherein said opaque area defines apeninsula.
 21. The window panel assembly as defined in claim 18, whereinsaid opaque area defines an island.
 22. The window panel assembly asdefined in claim 18, wherein said opaque area defines a strip.
 23. Thewindow panel assembly as defined in claim 22, wherein said strip isalong a centerline of the window panel.
 24. The window panel assembly asdefined in claim 18, wherein said attachment member includes at leastone selected from the group consisting of a polymeric bead, ahook-and-loop fastener, a post fastener, a double-sided adhesive tape,and an interlocking pin fastener.
 25. An overhead vehicle window panelassembly, comprising in combination:a window panel having inner andexterior surfaces; a storage compartment attached to said inner surfaceof said window panel, said storage compartment defining at least one ofa perimeter border, an island, a peninsula, and a strip extending acrosssaid inner surface; and an attachment member attaching said storagecompartment to said inner surface of said window panel.
 26. The windowpanel assembly as defined in claim 25, wherein said attachment memberincludes at least one selected from the group consisting of ahook-and-loop fastener, an interlocking pin fastener, a double-sidedtape, a post, and a polymeric bead.
 27. The window panel assembly asdefined in claim 25, wherein said polymeric bead includes an adhesivebonding said attachment member to said inner surface.
 28. The windowpanel assembly as defined in claim 27, wherein said adhesive is selectedfrom the group consisting essentially of single-component adhesives,multi-component adhesives, chemically activated adhesives, thermallyactivated adhesives, moisture-curable adhesives, thermoplasticadhesives, and thermoset adhesives.
 29. The window panel assembly asdefined in claim 28, wherein said multi-component adhesive includestwo-component urethanes.
 30. A window panel assembly for a vehicle,comprising in combination:a window panel having opposing surfaces, andconfigured to fit in a window opening of the vehicle; a storage assemblyattached to one of said opposing surfaces of said window panel; and anadhesive bonding said storage assembly to said window panel.
 31. Thewindow panel assembly as defined in 30, claim further including anopaque coating on said one opposing surface to conceal a bonding pointof said storage assembly from an opposite surface of said window panel.32. The window panel assembly as defined in claim 31, wherein saidstorage assembly is bonded to at least one of a perimeter, a peninsulararea, an island area, a strip area, and a centerline of said windowpanel.
 33. The window panel assembly as defined in claim 32, whereinsaid storage assembly includes at least one selected from the groupconsisting of a lighting system, an instrument display, a system controlpanel, a window panel shade, a hand grip, a sun visor assembly, and aninterior trim.
 34. The window panel assembly as defined in claim 33,wherein said storage assembly is bonded to said window panel prior toinstallation in the vehicle.
 35. The window panel assembly as defined inclaim 33, further including a plurality of attachment membersinterconnecting said storage assembly to said one opposing surfaces ofsaid window panel.
 36. The window panel assembly as defined in claim 35,wherein said attachment members include at least one selected from thegroup consisting of a hook-and-loop fastener, an interlocking pinfastener, a threaded fastener, a post, a double-sided tape, and apolymeric profile or bead.
 37. The window panel assembly as defined inclaim 30, wherein said vehicle accessory is detachable from said windowpanel.
 38. The window panel assembly as defined in claim 30, whereinsaid vehicle accessory includes overhead accessories.
 39. The windowpanel assembly as defined in claim 30, further including anadhesion-promoting compound between said two-component urethane and saidwindow panel.
 40. A vehicle window panel assembly, comprising incombination:a window panel having inner and outer surfaces terminatingin a peripheral edge, said edge of said window panel defining an upperedge to be located proximate an upper edge of a vehicle window opening;an opaque coating bonded to at least a portion of said inner surface ofsaid window panel proximate said peripheral edge; and at least one sunvisor assembly adhesively mounted to said opaque coating on said innersurface proximate said upper edge of said window panel.
 41. The vehiclewindow panel assembly as defined in claim 40, wherein said at least onesun visor assembly includes:a mounting member having one surface bondedto said opaque coating on said inner surface of said window panel; anarm pivotally coupled to, and extending from, said mounting member; anda sun visor panel pivotally attached to said arm.
 42. The vehicle windowpanel assembly as defined in claim 41, wherein said at least one sunvisor assembly, includes a bracket attached to said opaque coating andconfigured to receive at least one of said arm and said sun visor panelin a stowed position.
 43. The vehicle window panel assembly as definedin claim 41, wherein said at least one sun visor assembly includes:alamp assembly; and at least one of a power strip, and a pair ofconductors extending along said inner surface of said window panel forinterconnecting said lamp assembly to a power supply.
 44. The vehiclewindow panel assembly as defined in claim 40, further including anadhesive for bonding said at least one sun visor assembly to said opaquecoating.
 45. The vehicle window panel assembly as defined in claim 44,wherein said adhesive includes a two-component urethane adhesive.